Four-stage automatic valve for a water softener or conditioner



Apr 1963 R. E. SCHULZE ETAL 3,083,728

FOUR-STAGE AUTOMATIC VALVE FOR A WATER SOFTENER OR CONDITIONER Filed May 16. 1960 5 Sheets-Sheet 1 Indi n fansl laberf 51.90 711129- E'dwiri fi-morr'zsaw .W/QAWL if 3 Sheets-Sheet 2 SCHULZE ETAL R. E. FOUR-STAGE AUTOMATIC VALVE FOR A WATER SOFTENER OR CONDITIONER April 2, 1963 Filed May 16. 1960 v ww Z 1;. n i M April 2, 1 R. E. SCHULZE ETAL FOUR-STAGE AUTOMATIC VALVE FOR A WA 3,083,728 TER SOFTENER OR CONDITIONER 3 Sheets-Sheet 3 Filed May 16. 1960 EM g M5 & M d... v\

12 Claims.

The present invention relates to a novel automatic water softener or conditioner and more particularly to a novel valve combination and assembly for controlling the direction of liquid flow in automatic water softeners or conditioners during normal service, backwash and reactivation or regeneration.

In the co-pending application Serial No. 731,359, filed April 28, 1958, which has matured into Patent No. 3,006,- 376, a directional valve is disclosed having two parts or haives, one of which is connected to the inlet and the other to the outlet of a tank. One valve includes a pair of diaphragms with a port leading to a drain and a solenoid operated port. The other valve contains the eductor required to feed the salt brine to the tank for regeneration. These two valves are connected by a single conduit, thus eliminating any problems of spacing the valves on the tank.

Due to the valving arrangement of this prior application, the regeneration cycle for the tank does not provide the most efficient and effective regeneration of the water softening or conditioning material. In operation, this automatic softener gives a downflow service and an upfiow backwash, regeneration and rinse. Where, as in this previous case, a hard water rinse after regeneration is up how, some of the water softening material at the bottom of the tank becomes exhausted before the rinsing step is completed. Then, when the tank is placed in service, there is an initial hardness leakage due to the exhausted bottom layers.

To overcome this hardness leakage, the brine and rinse steps should be in a downfiow direction so that the hard water rinse will tend to partially exhaust a top layer of the water conditioning material during completion of the rinsing step. Next to a soft water rinse after brine, the downflow brine and hard water rinse is the most eficient procedure for regeneration.

in the present invention, the valve assembly is composed of two parts or halves, one being connected to the inlet and the other to the outlet. As in Patent No. 3,966,37 6, a conduit joins the two valves. However, the structure of the conduit in the present application includes a. second passage connecting the drain lines coming from both valve units and terminating in a single drain. A valve assembly is inserted in the drain conduit to control the flow of liquid issuing from each of the two drain lines.

Another important feature of the present invention is the utilization of a separate eductor system which feeds the brine for regeneration and the rinse water into the tank through a separate inlet in the top of the tank. In this way, be valve assemblies for the inlet and outlet of the tank remain in a less complicated and more troublefree condition.

A further important object of the present invention is the provision of a novel valve assembly combination which will effect the desired operational stages of downfiow service, upfiow backwash and downflow regeneration and rinse. The valve assembly is simplified in that the two parts or halves of the assembly are substantially identical, thus greatly simplifying replacement or repair of the assembly.

Another important object of the present invention is the provision of a drain conduit in the by-pass unit which communicates with the drain ports of both valves and nited States Patent ice terminates in a single drain passage. A flow control member is present in the by-pass conduit to regulate the backwash flow rate.

The present invention further comprehends a novel valve assembly in the bypass drain conduit to control the iquid flow through the two drain lines. Thus, when the backwash stage is in operation, the backwash water will force the valve in one direction to allow the backwash water to escape through the drain passage. When regeneration and rinse occur and liquid tends to pass through both outlet ports, the valve member tends to keep the drain port used for backwashing closed and allows the brine and rinse water to exit through the other drain port, thus effecting a downflow brine and rinse.

The present invention also comprehends a novel eductor assembly which is separate from both valve units and has a separate inlet leading into the tank. This eductor assembly is normally supported on the valve unit to which it is connected for the water supply required to operate the eductor. A flow controller in the eductor controls the dew rates for brine and rinse operations.

Other objects, advantages and features of the present invention include the provision of a fully hydraulic valve assembly with an automatic by-pass during backwash, regeneration and rinse so that a water supply is always available in the service line in the home. Further, the softener tank is isolated from both valves during the brine stage and, therefore, isolated from the normal hard water supply line. Also, the solenoid valves merely pass water from the hard water line and do not handle waste brine. The valve action is one of a short stroke, thus allowing efiicient operation over a Wide range of pressures.

Further objects are to provide a construction of maximum simplicity, efficiency, economy and ease of assembly and operation, and such further objects, advantages and capabilities as will later more fully appear and are inherently possessed thereby.

in the drawings:

FiGURE 1 is a view, part in front elevation and part in vertical cross section, of a four-stage automatic water conditioning system embodying the present novel automatic control valve assembly shown in front elevation above the service tank for the automatic control of this system.

FIG. 2 is an enlarged View in vertical cross section taken longitudinally and centrally through one of the valve control units shown in front elevation in FIG. 1.

FIG. 3 is an exploded view of the valve assembly combination including the eductor system and the by-pass and drain system showing the flow pattern for liquid during normal service operation.

FIG. 4 is an exploded view of the valve assembly combination showing the positions of the valve and the how pattern for liquid during backwash.

PEG. 5 is an exploded view of the valve assembly combination showing the positions of the valve and the flow pattern of the liquid during the brine and rinse stages of operation.

H8. 6 is an enlarged cross-sectional view of the drain unit to more fully show the structure of the novel check valve.

Referring more particularly to the disclosure in the drawings in which is shown an illustrative embodiment of the present invention of a directional valve assembly for controlling the operation of automatic water conditioners of the type shown in FIG. 1, including a portable service tank 7.6 containing a loose and relatively deep bed of treating minerals or material 11 disposed upon and above a gravel or filter bed 12 in the bottom of the tank and extending to the desired level or height but shown as spaced a suitable distance below the top of the tank to provide a free board space 13 thereabove.

The bed of treating minerals or material in the tank may be a resinous or siliceous ion exchange material or filter material which during the water softening or conditioning stage removes undesirable constituents or substitutes a sodium ion for the calcium or magnesium ions found in hard water until the material becomes exhausted resulting in a decrease in the quality of the effluent. the case of ion exchange, when the eflluent is substantially hard relative to the hard water entering the tank, the ion exchange material requires regeneration to replenish the sodium ions on the material. a

The service tank employed is of the general portable type provided with a coupling or fitting 14 whereby the tank may be quickly installed, removed or' replaced, when necessary. The coupling or fitting 14 is connected to an inlet tube or manifold -16 and an outlet tube or manifold 17, respectively. Each tube or manifold depends from the connector or fitting into the tank 10, the inlet manifold 16 extending into the tank only a few inches while the outlet manifold 17 extends into and through the ion exchange material and/or into the fi ter bed 12 terminating adjacent the bottom of the tank 10. The inlet manifold 16 is closed at the bottom and is provided with relatively wide slots 18 to permit uninterrupted flow of untreated water therethrough. The outlet manifold 17 is also closed at its lower end and provided with a finely slotted strainer section 19. The tank 10 differs from the normal service unit only in that an opening 21 is provided intermediate the inlet and outlet openings for the eductor 22.

When the bed of water conditioning minerals or material becomes exhausted and the material requires cleansing and/ or regeneration, it is contemplated that the valve assembly of the type here disclosed will accomplish the regeneration steps automatically and at frequent intervals, such as during a predetermined period in the night when. treated or softened water is not required in the service. line. To accomplish this automatic cycling, a two circuit adjustable timer is utilized which will not only initiate the regeneration cycle at a set time period during the night, but will also provide separate adjustment for the. backwash brine operations, depending on the amount. of sediment in the Water, the amount of salt used, the size of the tank and the volume of the content of ion, exchange material.

To accomplish the brining stage in the regeneration cycle, the present automatic water conditioning system contemplates a float valve and brine tank assembly of the type shown anddescribed in the pending application of Robert B, Schnlze and Edmund J., Heartstedt, Serial No. 643-,G43, filed;March 25, 1957-, now Patent-No. 2,920,644. It includes, a brine tank; 23. having a removable cover 24 for access to the salt chamber 25. A float chamber 26 is separated from the salt chamber by a partition or vertical wall 27. The float chamber contains a float valve assembly including a valve body 28. Through the top of the valve body 28 projects a float rod 29 having an adjustably mounted float ball 31 intermediate its ends and, above the valve body 28, Upper and lower ball retainers or positioners 32 and 33, respectively, for maintaining thejball in adjusted position are mounted on the float rod 29. above and below the ball. 7 A vertical conduit or pipe 34 communicates with a port 35 in the lower end of; the valve body 28 with its opposite end connected to a legnth of flexible tubing 36 leading to the central portion of the eductor 22. A substantially V-shaped guide member 37 having its diverging legs, anchored onto the pipe 34 guides. the vertical movementof the float ball 31 and its float rod .29. V

The valve body 28 consists of a cylindrical member 38 externally threaded at both. ends to accommodate a threaded cap or cover- 39 atitsupper end and an internally threaded base 41 atthe opposite end. The cap or cover 39 contains an; opening 42 through whichloosely extends the float rod 29. Gaskets or annular sealing rings 4 43 and 44 are provided at each end to seal the cap 39 and base 41 to the cylindrical body 38. The float rod 29 carries a conical valve 45 at its lower end, which valve when elevated seals the upper port or opening 42 by contacting the gasket 43.

Intermediate the length of the cylindrical member 38 is a transverse partition 46 tapering 0r dished toward the center and having a centrally disposed opening 47 communicating etween an upper chamber 48 and a lower chamber 49. A restricted passage 51 offset from the central opening 4-7 forms a by-pass between the chambers for flow when the central opening is closed.

The valve member 45 has a conical upper surface and a flat lower surface, said lower surface being diametrically slotted at 52 so that when the valve member 45 is lowered onto the partition 46, liquid will be permitted to flow from the upper chamber 48 to the lower chamber 49 by-passing through the slots 52. In the lower or air check chamber 49, a ball valve 53 made of plastic or other suitable buoyant composition unaflected by brine is located so that the ball valve will seal off the central opening 46 when in its elevated position and will sealoil passage 54 in the base 41 when in its lowered position. The passage 54- communicates with the conduit or pipe 34 which is suspended inoperative positionin the float chamber 26 by suitable connecting means 55.

To prevent free rotation of the ball valve 53 and maintain it in proper position, a depending tall or projection 56 is provided for the ball valve, with the depending tail extending through the gasket. 44 and into the bore orpassage 54;

The salt chamber 25 has a substantial capacity for receiving a large quantity of dry rock salt or saltpellets and' storing the salt along with a sterilizing agent to supply the brine requirements for a substantial period of time. The wall or partition 27 is provided with an opening 57 communicating between the twochambers. The positioners 32 and 33 onlthe float rod 29* are adjustable to vary the quantity of brine used in any one regenerationcycle. By adjusting the height of the float 3 1 on the float rod 29, the quantity of water admitted through valve 28 for dissolving salt in chamber 25' to produce brine. is varied. A gravel bed 58 is disposed in the bottom of chamber 25 to filter the brine prior to the exit of the brine into the float chamber 26 and into the service tank 10.

The novel valve assembly of the present invention for directing flow of water through the water conditioning system is more fully shown. in FIGS. '2 to 6. The assembly involves two substantially identical valve units, an eductor system and a by-pass unit having provision for the drain line coming from each valve unit. Sincethe valve units are substantially identical, only one will be describedwith likereference numerals having a superscript a showing like parts on the second valve. The valve unit 61 (FIG. 2) has a valve body 62 and a. connector 63 mating with. the fitting or coupling 14 on the service tank. The valve body 62 includes a main port 64, a. communicating passage 65, a central chamber 66, and a. by-pass port 67. A passage 68 communicates between the central chamber 66 and the connector 63. A hollow diaphragm cap. 69 is mounted on top of the valve body 62 and provides spaced chambers 71 and 72' joined by a connectingchannel 73. r

A valve stem 74 extends through a substantial length of the central chamber 66 and terminates in a threaded upper end 75 in the chamber 71. A resilient or rubber diaphragm 76 has a central portion 77 of. a substantial thic'knesswhich is secured to the valve :stem betweenupper andlower dished diaphragm plates 78- and 79. The lower diaphragm plate 79* is seated on an enlargement or shoulder 81 on the valve stem'74. and the upper diaphragm plate '79 bears against the central portion 77 of thediaphragm. 76and is held in placeby a lock nut 82v and lock washer 33 on the threaded upper end 75. The V outer periphery of the diaphragm 76 is clamped between the flanged periphery of the cap 69 and the valve body 62.

The valve stem 74 is substantially completely surrounded by a plunger tube 84. A second diaphragm 85 is secured to the plunger tube 34 by means of a sleeve 86 having an inwardly opening channel 87 and an annular shoulder for receiving the central part of the diaphragm 85. A collar 38 above the diaphragm 85 clamps the central portion of the diaphragm onto the shoulder. A snap ring 89 anchored to the plunger tube 84 abuts an annular flange on the sleeve 86, said flange locking the sleeve and collar 63 together due to the flange being formed over the adjacent edge of the collar. An O-ring 91 within the channel 87 provides for sealing contact with the exterior of the plunger tube 84.

The outer periphery of the diaphragm 85- is secured to the valve body 62 between a shoulder 92 formed on the inner surface of the valve body and a retainer ring 93. An externally threaded lock nut 94 is threadedly engaged with inner threads formed on the internal surface of the valve body 62 adjacent the shoulder 92 and bears against and retains the retainer ring 93. An expansion or coil spring 95 is seated at its lower end against the snap ring 559 adjacent the collar 88 with its upper end seated against the lower diaphragm plate 79.

The valve assembly in the valve body 62 includes the valve stem 74 having a conical valve 96 at its lower end and the plunger tube 84 encompassing but spaced from the valve stem to provide an annular passage therebetween. The plunger tube is longitudinally slotted at 97 at its upper end to provide space for the flow of liquid when the lower diaphragm plate 79 abuts the top of the tube.

At its lower end, the plunger tube has an enlargement 9? which is covered with an elastic or sealing covering forming a valve member 59 adapted to be lowered into contact with an annular valve seat 101 at the upper end of the connector 63 or raised into contact with an annular valve seat 162 in the valve body.

The chamber 72 communicating with chamber 71 through the passage 73 also communicates with the drain port 103 through an elastic flow control Hi4, an aligned opening in the upper diaphragm 76 and a passage 1115- opening into the drain port 163. The drain port 193 also communicates with the chamber formed between the upper diaphragm 76 and the lower diaphragm 85 through a passage 1%. The chamber 121 formed below the diaphragm $5 and above the valve seat 102 communicates with the by-pass port 67 in valve 61. In the valve 61 however, the by-pass port Til communicates with the chamber formed below the valve seat 102 and above the connector 63 This difference in construction between the two valves will become evident later. The main port 64 (shown more clearly in FIGS. 3, 4 and 5 and in dotted outline in FIG. 2) also is provided with a passage 1&7 leading to a cylindrical port 1133 having a filter screen 169. This port is connected to the chamber 71 through an aligned opening 111 in the diaphragm 76 and a port 112.

Into the junction of port 112 with the chamber 71 projects a plunger or valve member 113 of a solenoid valve 114, the operation of which is controlled by one circuit of a timer 115 (FIG. 1). The plunger 113 opens and closes the port 116 (PEG-S. 3, 4 and 5) at the junction of .e port 112 and chamber 71.

The outlet port 67 found in the valve member 61 communicates with the chamber 121) formed below the lower diaphragm 85 and above the valve seat 192 and connects the valve 61 to the eductor 22 through a passage 118. The eductor 22 includes a cylindrical body member 119 having a central passage 121 closed at the top end by a plug 122 threadedly engaging the body member 119. An O-ring 12 3 below the flange on the plug 122 seals the junction between the plug and the eductor body. The plug 122 also has a recess 125 in its lower end to accommodate the upper end of a filter screen 126, with the lower end of the screen resting upon a resilient flow regulator 127 having a constriction 128. The flow regulator 127 rests on a shoulder 129 formed on the surface of the central passage 121.

Immediately below the flow controller or regulator 127 is an inlet port 131 in a nipple 132 formed on the external surface of body member 119, the flexible tubing 36 from the vertical pipe 34 in the brine tank 23 being connected to the nipple. A tubular part 133 containing a throat or passage 134 for the eductor is mounted within the body member 119 by a flange 1'35 on the tubular part 133 engaging a second shoulder 136 on the surface of central passage 121. The tubular part 133 extends below the lower end of the eductor body member 119 and into the service tank.

The by-pass unit includes a by-pass part 137 and a drain part 138 shown thereabove in FIGS. 3 to 6, inclusive. The by-pass part 137 has a by-pass 139 connected at its opposite ends to the by-pass ports 67 and 70 in the valve units 61 and 61 respectively. The drain part 138 is connected at its opposite ends to the drain ports 163 and 103 of the valve units and contains a drain passage 14-1 housing a slidable check valve assembly 142. One end of the drain passage 141 is closed off by a plug 143 carrying a sealing O-ring 144. The connection from valve 61 enters through a side port 145 adjacent the end closed by the plug 143 and the other end of the drain part is shown terminating in an elbow 146.

The check valve assembly 142 includes a tubular body 147 open at the end adjacent the elbow 146 and terminates in an enlarged resilient conical head 148. The conical head 148 is adapted to seat against a washer 149 which is press-fitted into the passage 141 beyond one of its tapered reductions and seated against a shoulder 15%. A flow regulator 151 abuts the washer 149 on the side opposite the shoulder 150, the flow regulator being held in operative position by a snap or look ring 152 seated in a groove 158. Slots 153 are formed in the wall of the tubular body 147 adjacent the head 148 to allow liquid entering the tubular valve body to escape through a communicating port 154 arranged intermediate the ends of the drain part 138. An expansion or coil spring 155 is mounted in the passage 141 rearwardly of the valve head 148 with one end seated against a shoulder 156 formed adjacent the outlet port 154 and the opposite end seated against the shoulder 157 formed on the enlarged conical head 148. Thus the valve closes the passage from the port 145 until the pressure of the liquid passing through the flow controller or regulator 151 exceeds the pressure exerted by the coil spring 155.

The operation of the novel control valve assembly and brine tank, the position of the operative parts thereof and the path of flow during the four stages are as follows with reference to the flow diagrams in FIGS. 3, 4- and 5.

Normal Service With reference to FIG. 3, during normal service operation, hard water enters inlet valve 61 through the main port 64 and passes through the passage 65, main chamber 66, connectors 63 and 14 and the inlet manifold 16. The water passes down through the bed of ion exchange material 11; the calcium and magnesium ions being exchanged for sodium ions resulting in soft water. This softened water enters outlet manifold 17 through the strainer section 19, passes through the connectors 14 and 63 into the main chamber 66 of outlet valve 61 through the passage 65 and the main port 64 to the service line for the home or other user.

During the initial portion of the normal service stage, water also passes up through the port or opening 21 mounting the eductor, the tubular part 133 of the eductor, through the port 131 into the flexible tube 86 and downwardly through the vertical pipe 34 to the float valve body 28. Water can also pass through the flow regulater 127 of the eductor, through the filter screenv 126' and the passage 118 into the port 67 and valve 61 However, flow is stopped at that point by the lower diaphragm 85 and the enlargement -98 seated against valve seat 102. 7

As water enters the lower chamber 49 in the valve body 28 through the passage 54', it buoys up the ball valve .53 to seal the opening 46 leading to the upper chamber 48. The offset by-pass passage 51 allows water to slowly.

enter the upper chamber .48 and pass through the opening 42 since the valve member 45 is in its lowered position. The water passing'through' the opening 42 begins to fill the float chamber 26 and. passes into, the salt chamber 25 through the opening 57. Water continues to enter through the Valve body 28 until the level of th ewater contacts and lifts the float ball 31 and float rod 29 so that the valve member 45 closes the opening 42. The brine tank remains in this state with the salt in the salt chamber 25 being dissolved by the water during the remainder of the normal service stage.

During normal service, the solenoid plungers 113 and 113: are closed to stop any flow of water. through the' at line pressure, hereinafter designated (LP), from the. main port 64 to the tank 10 while the soft or. treated water emerging from the tank is under line pressure minus the pressure drop through the tank which is. the operating pressure, hereinafter designated (OP); Theline pressure (-LP), also exists in the passage 107' and chamber 108.:

The operating pressure (OP) also exists in the passage 107 chamber 108*, by-pass passage 139,. eductor 22, passage lls, flexible tubing" 36 and the brine tank" valve body 28.

Since the upper portions of. the valve assembly are cut off from" the water supply, atmospheric pressure, designated (AP), exists in these portions. atmospheric pressure exists inthe chambers between diaphragms 76 and 85' and diaphragrns 76 and 85 in.

chambers 71 and71 chambers 72.-and- 72 and in the drain part. 138.

Backwash With reference to FIG. 4, to initiate the backwash stage for this unit, one circuit of the timer 11-5 energizes the solenoid 114, thus retracting the solenoid plunger or valve member 113. Hard water enters the port 108 through the passage 107, passes through the filter screen 169, the aligned opening 111 in diaphragm 76,.port 112,

and the port 116 to enter the chamber'71. The water entering the chamber 71 exerts pressure onthe diaphragm. '76 forcing the valve stem 74 d0wnward,.thu 'open1ng theanuular passage in the plunger tube 84. The expansion spring. 95 on being compressed, urges the plunger tube 84 downward until the; enlargement 98 abuts the lower annular valve seat 101. Movement. of thevalve stem 74 continues until the lower diaphragm plate 79 abuts the upper end of the plunger tube 84.. Line pressure continues to hold the valve stem 74 and the. plunger tube 84 in their lowered positions during the backwash,

brine and rinse stages of the cycle} A small amountof water Will enter chamber. 72 through passage 73 and escape to the drain passage 141' through flow regulator 104 and drain port 103. a

With the connector 63 closed to the central chamber 66,

hard water entering through the main port 64 and passage 65 will flow through the annular space between the plunger tube 84 and the valve seat 102 to the by-pass Therefore, i

. 8 port67 and thence through by-pass 139, by-pass port 70 and the connector 63 into the tank. Water entering the tank emerges through the strainer section 19 of outlet manifold 17 and this water is forced up through the mineral bed 11 causing a swirling and circulating action to remove any dirt or sedimentation in the bed. Water passes through the slots 18 of the inlet manifold 16 and up through the connectors 14 and 63. The slots in the inlet manifold are of such dimensions that the ion exchange material is normally prevented from leaving the tank.

The backwash water coming up through the connector 63 passes into the annular passage formed between the valve stem 74 and the plunger tube 84, through the slots 97 and through the drain port 103 into the drain passage 141.. The flow regulator 151 controls the rate of flow of water during the backwashing stage. The backwash water is under sufficient pressure to overcome the force of the expansion spring 155 and forces the check valve 142 rearwardly to open and allow the backwash water to exit through the port 154.

During backwashing, the valve stem 74 and plunger tube 84 are in their upper positions to seal off the upper portion of valve 61 from the line pressure. The hard water is allowed to by-pass through the passage 65 and main port 64 to supply hard water for household demands.

In the backwashing operation, the untreated water at line pressure. (LP) enters the main port 64 and exits in the passage 107 and chamber 198. Line pressure is found in the chamber 71 exerting a downward force on the diaphragm 76; Line pressure also exists in by-pass ports 67 and '70 and in the by-pass 139. Line pressure enters. the tank through the connector 63* and remains.

in the service line from the main port 64 in valve member 61 Line pressure still exists in passage 107 and chamber 108*.

The backwash water emerging from the tank through the connector 63 is at line pressure minus the pressure drop in the tank or operating pressure (OP). Operating pressure now exists in the annular passage in the plunger tube 84, the drain port 163 and the drain passage 141 ahead of the flow regulator 151. Operating pressure still exists in eductor 22, outlet port 67 and passage 118, flexible tubing 36 and the brine tank valve body 28.

Regeneration With reference to FIG. 5, the regeneration stage of the unit is initiated when the second circuit of the timer 115 energizes the solenoid 114 causing the Withdrawal of the solenoid plunger 113*. Hard water coming from the by-pass 139 will enter passage 107* from passage p through the port 188", the filter screen 105,

the aligned opening 111 in the diaphragm 76*, port 112 and the port 116 to the chamber 71 to exert pressure on the topof the diaphragm 76 This pressure causes the valve stem 74 and the plunger tube 84* to descend, thus seating the enlargement 98 on the annular valve seat 191 and seating the lower diaphragm plate 79* on the top of the plunger tube 84*. A small amount of water will enter the chamber 72 through passage 73 and escape to the drain passage 141 through the flow regulator 104 and drain port 103?.

As seen in FIG. 5, both solenoids are activated to open position and both valve stems 74 and 74 and plunger I water line during regeneration except for the eductor 22.

To effect regeneration, hard Water enters the valve 61 through the main port 64-and passes through the passage 65, by-pass port 67, by-pass 139, and the -by-pass port 76 toenter the central chamber 66 of the valve 61 With the plunger tube 84 in its lowered position, the hard Water passes through the annular space between the plunger tube 84 and the annular valve seat 102 40 enter 9 the eductor 22 through the outlet port 67 and the passage 118. The hard water passes through the filter screen 126 and the flow regulator 127 to enter the depending tubular part 133. The flow regulator 127 controls the rate of flow of brine during the regeneration stage.

The pressure differential created by the water passing through the throat 134 in the tubular part 133 results in the creation of a vacuum at the inlet port 131. This vacuum draws the brine from the brine tank 23. As the initial amount of brine is drawn through the valve body 28, the liquid level in the float chamber 26 decreases, thus causing an initial lowering of the float ball 31, the float rod 29 and its valve 45. In drawing brine from the valve body 23, the ball valve 53 is drawn away from its upper valve seat to allow brine to pass through the central opening 46, but the ball valve still floats above the valve seat in the base 41.

As the brine begins to flow, the valve 45 on the float rod 29 is depressed to seat on the central partition 46 and the brine entering the upper chamber 43 passes through the slots 52 in the fiat lower surface of the valve 45, the central opening 47, the lower chamber 49 to the passage 54 in the base 41 leading to the vertical pipe 34, the flexible tubing 36, and the eductor 22. The brine entering the eductor 22 mixes with the hard water passing through the flow regulator 127 with the mixture entering the service tank through the opening 21. The brine flows downwardly through the mineral bed with the sodium ions in the brine being exchanged for the calcium and magnesium ions held by the ion exchange material 11, and the waste liquid or effluent enters the outlet manifold 17 through the strainer 19.

The waste liquid exiting from the outlet manifold 17 passes through the connectors 14 and 63 the annular passage between the valve stem 74* and the plunger tube 84 the slots 97 the drain port 103 and enters the drain passage 141 through the elbow 1%. The waste liquid flowing through the tubular check valve body 147 passes through the radial slots 153 therein and exits through the communicating port 154. The pressure of the liquid in the check valve body member 147 supplements the pressure exerted by the coil spring 155 to retain the resilient valve head 143 closed on its seat 149.

The waste liquid will also have a tendency to enter the valve 61 through the inlet manifold 16 and to enter the drain passage 141 through drain port 133. However, the pressure of the liquid passing through the drain port 103 cannot overcome the combined pressures of the coil spring 155 plus the waste liquid passing through drain port 193 so that the check valve 142 remains closed. It should be noted that during the regeneration stage, hard water is always available from the main port 64* of the outlet valve 61 to fulfill any household or other requirements.

When the brine in the brine tank 23 becomes exhausted, to prevent any air from being sucked into the eductor 22, the ball valve 53 sinks to seal off the passage 54 in the base 41 of the valve. At this point, all flow of brine or air ceases, and the ball valve 53 remains in this position until water is fed to the valve body 28 at the start of the next normal service stage.

During regeneration, the line pressure (LP) continues in the chamber 108 and 71 and in the by-pass 139'. Line pressure is also present at the main port 64 Further, line pressure (LP) is now found in the port 163 and the chamber 71 as well as in the passage 118 and the filter assembly of the eductor 22,. Operating pressure (OP) is found in the eductor 22] in the tubular part 133, the service tank 1%) and in the passages leading to drain port 193 Operating pressure is also found in the drain passage 141. A vacuum, hereinafter designated (S), exists in the flexible tubing 36, vertical pipe 34 and passage 54'.

R n e Again with reference to FIG. 5 of the drawings, the

fourth or rinse stage of the cycle occurs when the brine flow from brine tank 23 has ceased. All valve parts remain in their same positions with only hard water issuing from the eductor 22 to rinse away any excess brine in the service tank. The flow path of the waste liquid is the same as that found in the regeneration stage. The rinse stage continues until water from the connector 63 is soft. The line pressure (LP), operating pressure (OP) and vacuum (S) are found in the same passages and other elements as in the regeneration stage. When filter material alone is used in the tank 10, the brine stage will be omitted and the cycle will go directly to the rinse stage from the regeneration stage. The rinse stage is used for a filter material to flush untreated backwash water from the filter bed into the drain system.

Once the rinse stage of the cycle has been completed, the timer 115 simultaneously deactivates both solenoids 114 and 114 allowing the solenoid plungers 113 and 113 to advance to close off the ports 11d and 116. The pressure in chambers 71 and 71 decreases by relieving fluid through the passages 1G4 and 164 respectively, such that the water pressure acting on the diaphragms and 85 forces the plunger tubes 84 and 84 upward closing ofi the by-pass 139. The coil springs and 95 force the valve stems 74 and 74* upward, closing off the drain ports 1G3 and 103 Thus, normal service operation is restored in the system. At the beginning of the service cycle, water is fed to the brine tank 23 through the eductor 22 to produce suflicient brine for the next regeneration cycle.

Thus it can be seen that we have invented a new and novel automatic valve assembly which will give the most desirable regeneration characteristics; namely, an upflow backwash and a downflow brine and rinse. While there is shown a preferred embodiment, it is understood that the same is susceptible of modification and change, and comprehends such equivalents as are inherent in this disclosure and the claims.

Having thus disclosed the invention, we claim:

1. A directional valve assembly for controlling the direction and flow of liquid therethrough, comprising first and second valve bodies, a reciprocable valve member in each valve body, an upper, a lower, and an intermediate chamber in each valve body, sealing means surrounding each valve member and separating the upper chamber from the intermediate chamber, a valve seat between the intermediate and lower chambers cooperating with said valve member, an enlargement on the lower end of said valve member seating on said valve seat in one of the two valve positions, an outlet leading from said lower chamber of each valve body, a second valve seat cooperating with the enlargement on the valve member and separating the lower chamber from said outlet, a passage within said valve member which is closed when the valve is in normal position and is open when the valve enlargement seats on said second valve seat to provide communication between said outlet and said upper chamber, a drain port communicating with the upper chamber in each valve body, an inlet communicating with the lower chamber in the first valve body, a service outlet communicating with the lower chamber in the second valve body, a by-pass passage communicating between the intermediate chamber in said first valve body and the lower chamber in the second valve body, and an eductor port communicating with the intermediate chamber in said second valve body.

2. A directional valve assembly as set forth in claim 1, including an eductor communicating with the eductor port in said second valve body and further communicating with a source of brine,

3. A' directional valve assembly as set forth in claim 1, including a drain passage leading from said drain port in each valve body and communicating with a common drain, and a reciprocable check valve in said drain passages to selectively allow flow from one of the two drain ports.

4.- A directional valve assembly as set forth in claim 3, in which said reciprocable check valve includes a valve seat in said drain passage from said first valve body, a tubular valve body longitudinally movable in said drain passage and open at one end communicating with said second valve body, a sealing head on the opposite end of said tubular valve body and cooperating with said last mentioned valve seat, and resilient means normally biasing said sealing head against said valve seat.

5. A directional valve assembly as set forth in claim 1, in which said reciprocable valve member in each valve body comprises a plunger tube movable relative to said valve body and terminating at its lower end in said valve enlargement, and a valve stem within said plunger tube and spaced therefrom to form said passage in the valve member, and a valve at the lower end'of said valve stem normally closing said passage, said valve stem being movable relative to said valve body and to said plunger tube when the valve member is moved to its actuated position. v s

6. A directional valve assembly for controlling the direction and flow of liquid therethrough, comprising first and second valve bodies, a longitudinal chamber in each valve body and formed into upper, lower and intermediate valve chambers, a reciprocable valve member movable within said chambers, a diaphragm sealing member secured to the valve member and the valve'body and separating said upper and intermediate chambers, a valve seat for said valve member and separating said intermediate and lower chambers, said valve member including a valve stem movable relative to its valve body, a valve at the lower end of the valve stem, and a plunger tube encompassing but spaced from the valve stem to provide an annular passage therebetween and movable relative to its'valve body, an elongated'plunger valve on the lower end of the plunger tube and in normal position seated against said valve seat, said valve on said valve stemnormally closing the annular passage, a second valve seat formed at the lower side of'said lower chamber and receiving said plunger valve when in actuated position, a main inlet in said first valve body entering said lower chamber, an outlet leading from the second valve seat, a by-pass port communicating with said intermediate port in said first valve body, and a drain port communicating with said upper chamber and said annular passage in the valve member in said first valve body, a service outlet, aby-pass port and an outlet communicating with the lower chamber in said second valve body, an eductor port communicating with the intermediate chamber in the second valve body, and admin port communicating with the upper chamber and the annular passage in the valve member in the sec ond valve body, a by-pass passage connecting said bypass ports, a drain passage connecting said drain ports and leading to a common drain outlet, a check valve in said drain passage selectively allowing flow from one or the other of said drain ports, and an eductor communicating with said eductor port.

member, a sealing head on the valve member and extending into the drain passage from the first valve body, a valve seat in said last mentioned passage, a resilient spring urging the sealing head against the valve seat, said tubular valve member extending within and conformably fitting in the drain passage from the second valve body, and radial slots in said tubular valve member opposite said common drain outlet.

10. A directional valve assembly as set forth in claim 9, including a flow control in the drain passage from said first valve member to limit flow therefrom.

11. A directional valve assemblyas set forth in claim 5,

in which an actuating diaphragm is secured to the upper end of the valve stem and to the valve body and extends across the upper chamber.

12. A directional valve assembly for controlling the direction and flow of liquid therethrough, comprising first and second valve bodies each having an upper, lower and intermediate valve chamber, a reciprocable valve member movable within said chambers, a diaphragm sealing memher in each valve body secured to the valve member and its valve body and separating said upper and intermediate chambers, a valve seat for said valve member and separating said intermediate and lower chambers, said valve member including a valve stem movable relative to its valve body, a valve at the lower end of the valve stem, and a plunger tube encompassing but spaced from the valve stem to provide an annular passage therebetween and movable relative to its valve body, an elongated plunger Valve on the lower end of the plunger tube and in normal position seated against said valve seat, said valve on said valve'stem normally closing the annular passage, a second valve seat formed at the lower side of said lower chamber and receiving said plunger valve when in actuated position, a diaphragm actuating member spaced from said diaphragm sealing member and secured to the upper end of said valve stem and said valve body, said first valve body having a main inlet entering said lower chamber and an outlet leading from its second valve seat, a by-pass port communicating with said intermediate port in said first valve body, and a drain port communicating with said upper chamber and said annular passage in the valve member in said first valve body, a service outlet, a by-pass port and an outlet communicating with the lower chamber in said second valve body, an eductor port communicating with the intermediate chamber in the second valve body, and a drain port communicating with the upper chamber and the'annular passage in the valve member in the second valve body, a by-pass passage connecting said by-pass ports, a drain passage connecting said drain ports and leading to a common drain outlet, a check valve in said drain passage selectively allowing flow from one or the other of said drain ports, and an eductor communicating with said eductor port.

References Cited in the file of this patent UNITED STATES PATENTS 2,034,690 Anderson Mar. 24, 1936 2,265,225 Clark n Dec. 9, 1941 2,335,814 Stevenson Nov. 30, 1943 2,638,121 Dillman May 12, 1953 2,768,950 Kryzer Oct. 30, 1956 2,993,508 Wagner July 25, 1961 V FOREIGN PATENTS 1,044,952 France 19'53 

1. A DIRECTIONAL VALVE ASSEMBLY FOR CONTROLLING THE DIRECTION AND FLOW OF LIQUID THERETHROUGH, COMPRISING FIRST AND SECOND VALVE BODIES, A RECIPROCABLE VALVE MEMBER IN EACH VALVE BODY, AN UPPER, A LOWER, AND AN INTERMEDIATE CHAMBER IN EACH VALVE BODY, SEALING MEANS SURROUNDING EACH VALVE MEMBER AND SEPARATING THE UPPER CHAMBER FROM THE INTERMEDIATE CHAMBER, A VALVE SEAT BETWEEN THE INTERMEDIATE AND LOWER CHAMBERS COOPERATING WITH SAID VALVE MEMBER, AN ENLARGEMENT ON THE LOWER END OF SAID VALVE MEMBER SEATING ON SAID VALVE SEAT IN ONE OF THE TWO VALVE POSITIONS, AN OUTLET LEADING FROM SAID LOWER CHAMBER OF EACH VALVE BODY, A SECOND VALVE SEAT COOPERATING WITH THE ENLARGEMENT ON THE VALVE MEMBER AND SEPARATING THE LOWER CHAMBER FROM SAID OUTLET, A PASSAGE WITHIN SAID VALVE MEMBER WHICH IS CLOSED WHEN THE VALVE IS IN NORMAL 